Specification

DN100 PN40 Carbon Steel SS304 Manual Metal Seal Float Flange Ball Valve

I. Product Overview

TIANYU DN100 PN40 carbon steel and SS304 manual metal seal floating flange ball valve is a precision flow control device engineered for high-temperature, high-pressure industrial pipelines. As a floating ball design, it leverages media pressure to press the ball against the metal seat, achieving reliable sealing. Combining carbon steel (WCB) for structural strength and SS304 (CF8) for corrosion resistance, it handles media like oil, gas, steam, and industrial fluids. Equipped with manual operation and flange connections, it complies with international standards, serving as a durable shut-off solution in demanding industrial systems.

Parameter	Details
Material	Carbon Steel/ Stainless Steel
Structure	Worm Gear Operated Flanged Ball Valve
Size Range	DN15 – DN300 (1/2″ – 12″)
Pressure Rating	PN16 – PN40 (Class 150 – Class 300)
Connection Type	Flange (RF, RTJ)
Design Standard	API 608, ASME B16.34, GB/T 12237
Face-to-Face Standard	ASME B16.10, GB/T 12221
Flange Standard	ASME B16.5, DIN EN1092-1, JIS B2220
Testing Standard	API 598, ISO 5208
Temperature Range	-29°C to 200°C (-20°F to 392°F)
Operation Method	Worm Gear Operated
Seat Material	PTFE, RPTFE, PEEK
Application	Oil & Gas, Petrochemical, Water Treatment, Power Plants, etc.

II. Key Attribute Parameters

Size Range: DN15-DN600 (1/2″-24″), covering small to large-diameter pipelines to meet diverse flow requirements from equipment interfaces to main industrial networks.
Pressure Rating: PN16-PN40 (Class 150-Class 300), with PN40 (6.4MPa) as standard, suitable for medium to high-pressure systems like boiler feed lines and process pipelines.
Temperature Range: -29℃ to 425℃, with metal-sealed structure maintaining integrity in high-temperature environments (e.g., superheated steam) where soft seals would degrade.
Material Configuration:
- Body: Carbon steel (WCB, ASTM A216) for high structural strength, tensile strength ≥485MPa, yield strength ≥250MPa.
- Ball & Stem: SS304 (ASTM A182 F304) for corrosion resistance, with ball surface precision-ground to Ra ≤0.8μm.
- Seal: Metal-to-metal (SS304/Stellite alloy), ensuring tightness under thermal cycling and pressure fluctuations.
Connection Type: Flange (RF, ANSI B16.5), with bolt hole alignment matching pipeline standards for secure, leak-free integration.
Operation: Manual worm gear, reducing operating torque by 60% compared to direct lever operation, enabling easy handling even for large-diameter valves.
Standards Compliance: Design per API 608, ASME B16.34; testing per API 598; materials certified to ASTM standards, ensuring compatibility with global industrial systems.

Product Overview

III. Structural Features

Floating Ball Design: The ball is not fixed to trunnions but “floats” within the body. When media flows, pressure pushes the ball against the downstream seat, creating a self-tightening seal. This design eliminates complex trunnion structures, reducing weight while ensuring sealing reliability under varying pressures.
Metal-to-Metal Sealing: The ball and seat feature precision-machined, lapped metal surfaces (Ra ≤0.8μm). SS304 or Stellite-coated seats resist wear, corrosion, and high temperatures, outperforming soft seals in steam, abrasive, or chemical environments.
Manual Operation System: Equipped with a worm gearbox (cast iron housing) with a 30:1 transmission ratio, lowering manual force required to operate large-diameter valves. The handwheel (cast iron with anti-slip coating) includes position indicators for clear open/close status.
Safety Enhancements:
- Anti-blowout stem: Stem bottom features an inverted seal structure, preventing ejection under high pressure (API 600 compliant).
- Anti-static device: Stainless steel spring connects ball and body, dissipating static (resistance ≤10⁶Ω) to avoid sparks in flammable media.

IV. Manufacturing Processes

Material Selection & Inspection: Carbon steel and SS304 raw materials undergo spectral analysis to verify chemical composition (e.g., SS304: 18-20% Cr, 8-10.5% Ni). WCB forgings are ultrasonic-tested to eliminate internal defects.
Precision Machining:
- Ball & Seat: CNC grinders achieve ball roundness ≤0.01mm and surface finish Ra ≤0.8μm; seats are lapped to match ball contours, ensuring uniform contact.
- Body & Flange: CNC lathes machine flange sealing faces to flatness ≤0.05mm, with bolt holes drilled to ±0.1mm tolerance for pipeline alignment.
Assembly & Testing:
- Seal Assembly: Metal seats are pre-loaded with springs to compensate for thermal expansion, ensuring consistent contact with the ball.
- Performance Testing: Each valve undergoes:
  - Hydrostatic shell test (1.5×PN40 for 30 minutes) with no leakage.
  - Gas tightness test (0.6MPa nitrogen) with leakage ≤0.1×10⁻⁶ mL/s.
  - Operation test (100+ cycles) to verify smooth gear operation and position accuracy.
Surface Treatment: Carbon steel bodies are sandblasted (Sa 2.5) and coated with high-temperature anti-rust paint (dry film thickness ≥80μm); SS304 components are passivated to enhance corrosion resistance.

Valve Details

V. Product Advantages

Reliable High-Temp Sealing: Metal-to-metal sealing withstands 425℃, making it suitable for steam systems and high-temperature process lines where soft seals (PTFE) would melt or degrade.
Self-Tightening Performance: Floating ball design uses media pressure to enhance sealing, ensuring tighter shut-off as pressure increases—critical for preventing leaks in high-pressure pipelines.
Corrosion Resistance: SS304 ball/stem resist rust and chemical attack, while WCB body handles non-corrosive to mildly corrosive media, balancing durability and cost-effectiveness.
Easy Operation & Maintenance: Worm gear reduces operating force, and flange connection allows in-line maintenance (seat/ball replacement without removing the valve from the pipeline), lowering downtime.
Cost-Effective: Compared to trunnion ball valves, the floating design reduces material and manufacturing costs by 20-30% while meeting medium-high pressure requirements, ideal for budget-conscious projects.

Application

VI. Application Fields

Petrochemical Industry: Controls crude oil, refined products, and chemical intermediates in storage tanks, transfer pipelines, and reactor feed lines, with SS304 components resisting mild corrosion.
Power Generation: Regulates high-temperature steam in boiler systems, turbine bypass lines, and condensate networks, where metal sealing withstands 425℃ steam without degradation.
Industrial Heating: Manages hot oil and thermal fluids in district heating networks and process heating systems, ensuring reliable shut-off to prevent energy loss.
Water Treatment: Controls high-pressure water in desalination plants and industrial water circulation systems, with SS304 parts resisting scale and mineral deposits.
General Manufacturing: Used in compressed air lines, hydraulic systems, and fuel supply pipelines, providing durable shut-off for diverse industrial media.